Senior Mechanical Engineer

TP-Link Systems USA; Irvine (CA); On-site; USD 145,000 - 155,000; Full time

Benefits offered by this job

Med, dental & vision coverage

401k plan

PTO (4 weeks)

Bi-annual pay raises

Free gym membership

Team-building events

Job summary

TP-Link Systems Inc. in Irvine, CA seeks a Senior Mechanical Engineer to own the product-level mechanical architecture and drive mass-produced designs for Wi-Fi routers and gateways. You will partner with ID, Electrical/Hardware, and suppliers to deliver robust, cost-aware solutions from concept through EVT/DVT/PVT.

You will mentor junior engineers, lead DFA/DFM decisions, and ensure ECO-driven documentation control while supporting tooling and prototype builds. Travel up to 10% is expected.

Qualifications

• BS in Mechanical Engineering; MS preferred.
• 7+ years in mechanical product development for consumer electronics or similar.
• Proficient with PTC Creo; able to produce release-ready CAD/Drawing/BOMs.
• Strong plastics/metals, GD&T, tolerance stack-up knowledge; high-volume manufacturing.

Responsibilities

• Own mechanical system architecture, internal layout, and assembly strategy.
• Collaborate with Industrial Design and Electrical/Hardware to define interfaces.
• Support thermal/EMI mechanical integration and grounding strategies.
• Create and release drawings, BOMs, and ECO-driven documentation.
• Plan prototype builds (EVT/DVT/PVT) and drive closure of issues.
• Lead supplier/toolmaker engagement and DFA/DFM decisions.
• Mentor junior engineers and participate in design reviews.

Skills

PTC Creo

GD&T

Tolerance analysis

Cross-functional leadership

Mechanical design

DFM/DFI

Supplier engagement

ECOs / change control

Education

B.S. in Mechanical Engineering

M.S. preferred

Tools

Creo

Job description

Description About Us

Headquartered in the United States, TP-Link Systems Inc. is a global provider of reliable networking devices and smart home products, consistently ranked as the world’s top provider of Wi-Fi devices. The company is committed to delivering innovative products that enhance people’s lives through faster, more reliable connectivity. With a commitment to excellence, TP-Link serves customers in over 170 countries and continues to grow its global footprint. We believe technology changes the world for the better! At TP-Link Systems Inc, we are committed to crafting dependable, high-performance products to connect users worldwide with the wonders of technology. Embracing professionalism, innovation, excellence, and simplicity, we aim to assist our clients in achieving remarkable global performance and enable consumers to enjoy a seamless, effortless lifestyle.

Overview

TP-Link Systems Inc. is seeking a talented and driven Senior Mechanical Engineer to join our team in Irvine, CA. In this role, you will own the mechanical system architecture (internal layout, construction strategy, and assembly approach) and detailed mechanical design of next-generation consumer networking and smart home products—primarily Wi Fi routers / mesh nodes / gateways. You will take products from early concept through high-volume manufacturing, working closely with Industrial Design (ID), Electrical/Hardware Engineering, NPI/Operations, and external suppliers/contract manufacturers to deliver production-ready designs.

Key Responsibilities

• Own and drive product-level mechanical system architecture, including internal layout, part breakdown strategy, construction strategy, fastening/joining strategy, datum scheme, tolerance strategy, and serviceability.
• Partner with Industrial Design (ID) to translate design intent into manufacturable mechanical solutions while balancing aesthetics, usability, reliability, schedule, and cost.
• Collaborate with Electrical/Hardware Engineering to define mechanical interfaces and constraints, including PCB outline and mounting, connector/I-O access, assembly datums, fastener strategy, and key keep-outs (as applicable).
• Support thermal and EMI-related mechanical integration, including thermal conduction/heat-spreading paths, shielding strategy implications (contact/compression features, gasket interfaces, conductive coatings), and grounding/contact reliability across tolerance and assembly variation.
• Create and release deliverables using PTC Creo (Creo Parametric): 3D CAD, 2D drawings, specifications, and (preliminary and released) BOMs; apply GD&T and tolerance stack-up on critical interfaces.
• Plan and support prototype builds and validation (EVT/DVT/PVT or equivalent): define build objectives and acceptance criteria; evaluate fit/function, cosmetic, key dimensions, and assembly robustness; drive issue closure through subsequent builds.
• Lead supplier/toolmaker engagement including tooling kick-off and T0/T1/Tn iterations; coordinate mold tuning and dimensional/assembly issue closure with suppliers/CMs.
• Drive DFM/DFA decision-making across manufacturing processes (injection molding, CNC machining, sheet metal, die casting, secondary ops/finishes), including cost/schedule trade-offs.
• Own documentation quality and change discipline: release and maintain drawings/BOMs and drive Engineering Change Orders (ECOs) with clear revision control and supplier communication.
• Participate in root-cause analysis and corrective actions for mechanical issues found during builds, in production, or from field returns.
• Mentor junior engineers through design reviews, best practices, and hands-on coaching (scope/expectations vary by leveling).

Qualifications

• B.S. in Mechanical Engineering or related field; M.S. preferred.
• 7+ years of hands-on mechanical product development experience in consumer electronics, networking products, or electro-mechanical products, including ownership from concept through mass production and demonstrated cross-functional technical leadership.
• Strong proficiency with PTC Creo; able to independently produce release-ready part/assembly CAD, drawings, and BOMs.
• Strong fundamentals in plastics/metals, injection molding, tooling iteration, tolerance/GD&T, and high-volume manufacturing considerations.
• Strong communication skills and demonstrated ability to work effectively in a fast-paced, cross-functional environment.
• Willingness to travel up to 10% to support suppliers/CMs as needed.

Preferred Qualifications

• Experience with compact, high-volume consumer electronics (routers/mesh nodes/gateways or similar products).
• Experience working directly with CMs/toolmakers and closing issues through tooling iterations (T0/T1/Tn).
• Experience working with suppliers, ODM/JDM partners, or contract manufacturers in Taiwan, China, Vietnam, or other Asia-based manufacturing ecosystems.
• Familiarity with rapid prototyping (3D printing, CNC prototypes, soft tooling) and hands-on build/debug support.
• Familiarity with structural simulation/FEA and vibration/shock fundamentals.
• Exposure to PLM/PDM tools and controlled release workflows.

Interview Materials (Remote-Friendly)

Please provide a portfolio (PDF) or be ready to present work samples via screen-share. Confidential details may be redacted.

Benefits

Salary Range: $145,000 - 155,000

• Fully paid medical, dental, and vision insurance (partial coverage for dependents)
• Contributions to 401k funds
• Over four weeks of PTO per year
• Bi-annual pay increases
• Health and wellness benefits, including free gym membership
• Quarterly team-building events

At TP-Link Systems Inc., we are continually searching for ambitious individuals who are passionate about their work. We believe that diversity fuels innovation, collaboration, and drives our entrepreneurial spirit. As a global company, we highly value diverse perspectives and are committed to cultivating an environment where all voices are heard, respected, and valued. We are dedicated to providing equal employment opportunities to all employees and applicants, and we prohibit discrimination and harassment of any kind based on race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state, or local laws. Beyond compliance, we strive to create a supportive and growth-oriented workplace for everyone.

Please, no third-party agency inquiries, and we are unable to offer visa sponsorships at this time.

TP-Link is a leading provider of consumer Wi-Fi networking products. We continuously develop new products and technologies that transform the way people connect. Our networking expertise uniquely positions us as a leader in emerging technologies that improve our everyday lives, such as smart home products. Spacious and modern, our US offices create a casual atmosphere that fosters team collaboration. In addition to free snacks and drinks, TP-Link Systems Inc. offers a modern working environment, free gym membership, quarterly team building, flex-spending, employee paid benefits, bi-annual raise opportunity, paid vacation & holidays, 401k plan and annual bonus opportunity.